An Aerosolization Module for an Aerosol Generating System Having an Optimized Configuration

ABSTRACT

An aerosolization module for an aerosol generating device includes a reservoir configured to contain a vaporizable material, a heater including a wick which is configured to imbibe liquid by capillarity, and a liquid path for providing liquid from the reservoir to the heater that includes at least one liquid channel that fluidically connects the reservoir to the wick, the liquid channel including a porous pad in contact with the wick. The porous pad improves the reliability in the supply of vaporizable material to the heater.

FIELD OF THE INVENTION

The present invention relates to an aerosolization module for an aerosol generating system.

Aerosol generating systems allow vaporization of a product, generally a liquid, often called e-liquid or e-juice. The aerosol generating systems according to the invention are also commonly called vaporizers or electronic cigarettes.

More particularly, vaporization of the product is obtained, generally by heating, in an aerosolization module, also called atomizer. Aerosolization is the conversion of a substance, for example in liquid state or solid state, into particles small and light enough to be transported in the air.

Aerosol generating systems or e-cigarettes are thus portable devices comprising an electric heat source, included in an aerosolization module, that heats the product (e-liquid) to create an aerosol that the user inhales, and a battery to power the heat source.

BACKGROUND OF THE INVENTION

Several atomizer technologies and configurations are known for aerosol generating systems. Such atomizers usually include a reservoir filled with e-liquid known as “cartomizer”, the contraction of cartridge and atomizer, “clearomizer” when the cartomizer's reservoir is clear from any porous liquid material therein, etc. They typically use an electric powered heating device. A battery that is comprised in a battery module provides electric power to the heating device. The battery module and the aerosolization module can be formed as a one-piece system, but they are generally provided as separate modules.

The aerosolization module generally comprises the reservoir which is filled with vaporisable material to be aerosolized by the heater.

The term vaporizable material is used to designate any material that is vaporizable in air to form an aerosol. Vaporisation is generally obtained by a temperature increase up to the boiling point of the vaporization material, such as at a temperature up to 400° C., preferably up to 350° C. The vaporizable material may, for example, comprise or consist of an aerosol-generating liquid, gel, or wax or the like, or any combination of these.

Several configurations of aerosolization module are known, which make it possible provide the heater with vaporizable material.

US9596887 B2 discloses an electronic cigarette provided with a housing comprising a liquid reservoir, an atomizer which is a heater and an aerosol outlet. The heater is provided in an atomizing chamber comprising a wick aperture. A wick disposed through the wick aperture between the liquid reservoir and the atomizing chamber is configured to transfer the liquid by capillarity from the liquid reservoir to the atomizer.

However, this configuration can be optimized to provide liquid to the wick at a more regular rate, i.e. to avoid any fluctuation in the supply of liquid to the wick, for example depending on changes in orientation of the vaporizer.

The present invention aims to provide an aerosolization module that has a simple configuration making it easy to produce and to assemble while addressing the aforementioned problem.

SUMMARY OF THE INVENTION

The present invention thus relates to an aerosolization module for an aerosol generating device. The aerosolization module comprises a reservoir adapted to contain a vaporizable material arranged near a mouthpiece end of the aerosolization module. The aerosolization module comprises a heater configured for liquid aerosolization; the heater comprising a wick which is adapted to imbibe liquid by capillarity, the heater being arranged between the reservoir and a power supply connecting end. The aerosolization module comprises a liquid path for providing liquid from the reservoir to the heater. The liquid path comprises at least one liquid channel fluidically connecting the reservoir to the wick, the liquid channel comprising a porous pad in contact with the wick. The porous pad is arranged between the heater and the power supply connecting end, such that the liquid flows substantially in a direction from the power supply connecting end toward the mouthpiece end over a portion of the liquid path.

Such configuration makes it possible to obtain a compact aerosolization module, with an optimized location of the parts which it comprises. Such configuration also provides a good regulation of the flow of liquid that imbibes the wick. The porous pad retains a small quantity of liquid available for imbibing the wick of the heater, and the wick is supplied with liquid regardless of the orientation of the aerosolization module. Because the wick is placed above the porous pad in to the usual position of use of the aerosol generating device, the resulting capillary imbibition provides a regular supply of liquid to the wick and the heater. The porous pad forms a small liquid buffer that regulates the flow of vaporizable product in liquid form from the reservoir to the wick. It avoids or reduces fluctuations in the supply of liquid to the wick, that could be caused by a movement of the aerosolization module (or of the aerosol generating device comprising the aerosolization module).

The vaporizable material can be a liquid to be aerosolized or a material that can be transformed into a liquid to be aerosolized.

The porous pad can be made of cotton.

Cotton has suitable retention properties but many other materials with similar properties can be used successfully.

The at least one liquid channel can extend from the reservoir to a chamber located between the heater and the power supply connecting end, said chamber containing the porous pad.

The reservoir can be formed as a single part having at least one external wall, and the at least one liquid channel can be arranged along said external wall of the reservoir.

This provides an optimal integration of the channel or channels in the aerosolization module.

The aerosolization module can further comprise a heater holder, the porous pad being interposed between a side portion of the heater holder and a lateral end portion of the heater.

This position of the porous pad makes it possible to reliably supply the vaporizable material to the heater, which generally comprises a wick that extends along the heater and protrudes or is exposed at the ends of the heater, and by capillarity imbibes liquid to be vaporized contained in the porous pad. This also frees the central portion of the heater. This makes it possible to supply the central portion of the heater with air in which the liquid is to be vaporized.

The heater and/or the heater holder comprises contacts for electrical connection which are integrated using insert molding.

The electrical connections allowing the supply of electricity to the heater are thus integrated in the heater or in the heater holder, thus reducing the space used for these connections. This also greatly simplifies the assembly of the aerosolization module.

The aerosolization module can comprise two liquid channels and two porous pads, each of said porous pads being in contact with a respective extremity of the wick of the heater.

This allows a better supply to the wick with liquid to be vaporized, and allows a good supply to the wick in many orientations of the module.

The reservoir can comprise a central tube, the heater being placed at the bottom of said central tube.

The central tube is thus configured for the flow of the aerosol generated by the heater by vaporization of the vaporizable materiel in air.

A spatial optimization of the aerosolization module can be obtained thanks to one or several of the following features:

-   -   the reservoir can comprise a first volume and a second volume         having a symmetrical arrangement around the central tube, each         of the first volume and the second volume being fluidically         connected to a distinct liquid channel;     -   the heater can have an elongated shape and extend substantially         orthogonally to the central tube;     -   the aerosolization module can comprise a heater cover which         comprises a hole sealingly fastened to the central tube;     -   each liquid channel can be formed between external walls of a         part forming the reservoir and the heater cover;     -   a silicone seal can be interposed between the hole of the heater         cover and the central tube;     -   a silicone part can be interposed between the heater cover and         the heater.

BRIEF DESCRIPTION OF THE DRAWINGS

Other particularities and advantages of the invention will also emerge from the following description.

In the accompanying drawings, given by way of non-limiting examples:

FIG. 1 represents, in a schematic sectional view, an aerosolization module according to an embodiment of the invention;

FIG. 2 represents, in a schematic exploded view, the aerosolization module of FIG. 1 .

DETAILED DESCRIPTION

FIG. 1 represents an aerosolization module according to an embodiment of the invention, whose assembly will be better understood thanks to FIG. 2 .

The aerosolization module comprises a reservoir 1. The reservoir 1 has at least one wall 2. The reservoir 1 defines an inner volume 3 that is adapted to contain a vaporizable material. The reservoir can be, by way of example, a one-piece plastic part, for example obtained by injection moulding.

The vaporizable material can be in liquid form, in solid form, or in a semi liquid form (paste, gel, wax, etc.), or in a combination thereof.

Thus, the vaporizable material can be a liquid or a non-liquid material that can be transformed into a liquid to be aerosolized.

Vaporisation is obtained by heating the vaporizable material. To this end, the aerosolization comprises a heater 4. The heater 4 is configured to perform aerosolization of the vaporizable material.

The heater 4 comprises heating means such as a resistive element, such as a resistive wire that can be coiled.

The heater 4 also comprises a wick 5. The wick 5 is made of a material that is adapted to imbibe liquid by capillarity, for example a textile material.

The wick 5 of the heater 4 is provided with liquid from the reservoir by a liquid path. The liquid path comprises a channel 6 that fluidically connects the reservoir 1 (and more particularly the inner volume 3 of the reservoir 1) and the wick 5 of the heater 4.

The capillary displacement of the vaporizable material is effected on the material in a liquid state. If not already provided by the reservoir as a liquid, the heat energy of the heater induces the transformation of the vaporizable material into a liquid state. This may for example be the case if the reservoir 1 contains a vaporizable material consisting of or comprising a wax.

The liquid channel comprises a porous pad 7 which is in contact with the wick 5. The porous pad 7 is formed of a material that can imbibe and retain liquid. The porous pad is advantageously made of cotton, but many fibrous and/or textile materials can be used with success.

The porous pad 7 regulates the flow of liquid that imbibes the wick 5, and retains a small quantity of liquid, regardless of the orientation of the aerosolization module. This small quantity of liquid is thus available for imbibing the wick 5 of the heater 4.

In the represented embodiment, the heater 4 is supported by a heater holder 8. The heater 5 and the heater holder 8 constitute a heater assembly which is rigidly fixed to the reservoir 1. More particularly, in the represented embodiment, the heater holder 8 closes, in combination with a sleeve 9 and with an optional bottom plate 10, the bottom end of the reservoir 1.

The aerosolization module comprises electrical contacts 11 that are configured to provide the heater with electricity.

The electrical contacts can be electrical plugs configured to mate with spring pin connectors, usually called “pogo pins^(TM”). A spring pin connector is usually made up of two sliding cylinders constrained against each other by an internal spring. Other types of electrical contact can be used, for example electrical contacts configured to cooperate with plate spring contacts. In the represented embodiment, the electrical contacts are embedded, e.g. by insert molding, in the heater holder 8. The bottom face of the aerosolization module thus forms a power supply connecting end 12.

The connection of the aerosolization module to a corresponding battery module constitutes an aerosol generating device.

It should be noted that the aerosolization module can be a consumable item of the aerosol generating device. It can also be designated by the term “cartridge”. Once the vaporizable material initially contained in the reservoir has been consumed, and the reservoir is empty, the aerosolization module is replaced by another aerosolization module with a full reservoir. The old module can be discarded, preferably for recycling. A change of aerosolization module can also be carried out, even before the reservoir is empty, in order to change the product to be vaped. This allows for example the user to choose the taste of the product consumed.

The reservoir 1 can comprise or can form a mouthpiece 13 at an upper end which is an opposite end to the power supply connecting end 12. The mouthpiece is the part of the aerosol generating device where the user's mouth is placed to vape, i.e. to inhale the aerosolized product.

A central tube 14 connects the mouthpiece 13 to the heater 4 where the aerosol is formed. Air is provided to the heater 4 for example from the bottom of the aerosolization module, through a check valve 15.

In the represented embodiment, the central tube 14 is mainly formed by the reservoir 1.

The heater 4 is placed at the bottom of the central tube 14.

The heater 4 is capped by a heater cover 16. The heater cover 16 comprises a hole 17 that is aligned with the central tube 14. A seal 16 is interposed between the bottom end of the central tube 14 and the heater cover 16. The seal 18 provides good and reliable fluid-tightness between the inner volume 3 of the reservoir 1 and the central tube and the heater cover 16. The seal 18 also provides a good and reliable fluid-tightness between the central tube 14 and the hole 17 of the heater cover 16. The seal is preferably made of silicone. Other materials having sealing properties can be used alternatively.

A spacer, for example a silicone part 18, is interposed between the heater 4 and the heater cover 16. The silicone part 18 comprises a central aperture 19, allowing the aerosol formed by the heater to reach the central tube 14.

The heater 4 has an elongated shape. The wick 5 extends substantially in the same direction as the heater. In the represented embodiment, the heater 4 extends substantially orthogonally to the central tube 14. This saves space in the longitudinal direction (i.e. from the bottom or supply connecting end of the vaporization module to its top end comprising the mouthpiece 13). While other configurations of the heater can be used, for example vertical configurations in which the heater extends in the longitudinal direction, the heater configuration of FIG. 1 is preferred.

In this configuration, the liquid channel is formed between external surface of the walls 2 of the reservoir and the heater cover. The channel can thus be formed along the inner surface of the wall 2, or it can be formed in the wall 2.

More particularly, the channel 6 issues into a chamber 20 located under the heater 4, i.e. between the heater 4 and the power supply connecting end 12. The porous pad 7 is contained in this chamber 20. The porous pad has a shape that is adapted to the chamber 20, and completely fills this chamber. The porous pad can be slightly compressed in the chamber 20, but must be able to imbibe liquid.

In such configuration, the wick 5 comes out from under the heater, and, more particularly, from a lateral end portion 21 of the heater 4.

The position of the porous pad under the heater has many advantages. It saves space in the transverse direction. Furthermore, because the wick is supplied with liquid by capillarity, the liquid distribution is regular and smooth.

The represented embodiment of the invention has an advantageous symmetrical arrangement. The reservoir 1, and more particularly its inner volume 3 thus comprises a first volume 22 and a second volume 23 having a symmetric arrangement around the central tube 14. The first volume 22 and the second volume 23 can be independent, but are preferably in fluidic communication to ensure that the level of vaporizable material in each volume of the reservoir remains equal at all times.

In this configuration, each of the first volume and the second volume of the reservoir 1 is fluidically connected with a distinct liquid channel 6 configured to supply vaporizable material to the heater 4. The aerosolization module thus comprises two liquid channels 6, two chambers 20, and two porous pads 7. The wick 5 of the heater is so imbibed from each of its two ends. Indeed, the wick 5 is exposed at each end of the heater, e.g. under each end portion of the heater. This enhances the reliability of provision of liquid whatever the orientation of the module.

The aerosolization module provided in the invention, which comprises a porous pad that forms a small liquid buffer makes it possible to imbibe the wick of the heater in a regular and smooth manner. Furthermore, the provision of vaporizable material to the heater is reliable, and can be continued a certain time despite unfavorable orientations of the aerosolization module.

References used for the figures 1 Reservoir 2 Wall 3 Inner volume 4 Heater 5 Wick 6 Liquid channels 7 Porous pads 8 Heater holder 9 Sleeve 10 Bottom plate 11 Electrical contact 12 Power supply connecting end 13 Mouthpiece 14 Central tube 15 Check valve 16 Heater cover 17 Hole 18 Silicone part 19 Central aperture 20 Chamber 21 Lateral end portion 22 First volume 23 Second volume 

1. An aerosolization module for an aerosol generating device comprising: a reservoir configured to contain a vaporizable material arranged near a mouthpiece end of the aerosolization module, a heater configured for liquid aerosolization; the heater comprising a wick which is configured to imbibe liquid by capillarity, the heater being arranged between the reservoir and a power supply connecting end, a liquid path for providing liquid from the reservoir to the heater, the liquid path comprising at least one liquid channel fluidically connecting the reservoir to the wick, the at least one liquid channel comprising a porous pad in contact with the wick, wherein the porous pad is arranged between the heater and the power supply connecting end, such that the liquid flows substantially in a direction from the power supply connecting end toward the mouthpiece end over a portion of the liquid path.
 2. The aerosolization module according to claim 1, wherein the porous pad is made of cotton.
 3. The aerosolization module according to claim 1, wherein the at least one liquid channel extends from the reservoir to a chamber located between the heater and the power supply connecting end, said chamber containing the porous pad.
 4. The aerosolization module according to claim 1, wherein the reservoir is formed as a single part having at least one external wall, and the at least one liquid channel is arranged along said at least one external wall of the reservoir.
 5. The aerosolization module according to claim 1, wherein further comprising a heater holder, the porous pad being interposed between a side portion of the heater holder and a lateral end portion of the heater.
 6. The aerosolization module according to claim 5, wherein the heater and/or the heater holder comprises embedded contacts for electrical connection.
 7. The aerosolization module according to claim 1, wherein the at least one liquid channel comprises two liquid channels and the aerosolization module further comprises a second porous pads, each of said porous pads being in contact with a respective extremity of the wick of the heater.
 8. The aerosolization module according to claim 7, wherein the reservoir comprises a central tube, the heater being placed at a bottom of said central tube.
 9. The aerosolization module according to claim 8, wherein the reservoir comprises a first volume and a second volume having a symmetrical arrangement around the central tube, each of the first volume and the second volume being connected to a distinct one of the two liquid channels.
 10. The aerosolization module according to claim 8, wherein the heater has an elongated shape and extends substantially orthogonally to the central tube.
 11. The aerosolization module according to claim 8, wherein further comprising a heater cover which comprises a hole sealingly fastened to the central tube.
 12. The aerosolization module according to claim 11, wherein further comprising a spacer interposed between the heater and the heater cover.
 13. The aerosolization module according to claim 11, wherein each of the at least one liquid channel is formed between external walls of a part forming the reservoir and the heater cover.
 14. The aerosolization module according to claim 11, wherein a silicone seal is interposed between the hole of the heater cover and the central tube.
 15. The aerosolization module according to claim 11, wherein further comprising a silicone part interposed between the heater cover and the heater. 